DE102021201835B4 - Part of a luggage system comprising a natural fiber material and methods for its manufacture and repair - Google Patents

Abstract

Part (21; 31; 400) of a luggage system, in particular shell (510; 520) of a hard case or trolley (500), comprising a fiber-reinforced material (100a; 100b; 100c), the fiber-reinforced material comprising: 1a. a natural fiber material (110a; 110b; 110c); and1b. a matrix material (130a; 130b; 130c), wherein 1C. the natural fiber material comprises at least one set (120a; 120b-121b; 120C-123e) of unidirectional fibers incorporated into and/or impregnated with the matrix material; undid. wherein the natural fiber material is provided as a layered fabric.

Description

1. Technical field

The present invention relates to a luggage system or a part of a luggage system, in particular a shell of a hard case or trolley or a part of such a shell, comprising a natural fiber material. The present invention also relates to a method for manufacturing and a method for repairing such a luggage system or a part of a luggage system.

2. State of the art

Material fibers of plastic, carbon or E-glass have been used in the rolling luggage industry for decades in both woven and non-woven patterns suspended in a suitable matrix material for their ability to provide strength in a number of areas such as tensile , to increase the tear and torsional stability of the luggage. While these composite materials can achieve high levels of mechanical performance, poor processing and environmental conditions can easily weaken or break them.

Regardless of the cause, if such a composite shell fails, there is no chance of repair, only replacement. The individual materials that make up the composite material in the broken shell would have to be separated individually in order to be reused in modern recycling plants through heat or mechanical or chemical processes. Globally, composites are almost never recycled because the materials contained are difficult to separate, the energy required for separation is high, and the economic incentive is lacking.

Since the materials contained in the known composites are inorganic and potentially or already known to pollute the environment during their extraction and processing, and since their end of life is almost exclusively landfill, the life cycle assessment for the world's strongest composites in the luggage industry surprisingly short and with negative environmental impacts both at the beginning and at the end of their lives.

However, for most consumers, environmental sustainability is a key attribute that they want to find in almost every product. It is often said that sustainability and durability are opposites at all costs and that one must be sacrificed for the other, always leaving the customer with a compromise.

Some considerations on the use of natural fibers were discussed in the document US 3,383,272A which describes a shaped, rigid product having contoured and non-contoured parts, the product being derived from a resin-impregnated fibrous mass comprising a multiplicity of fibres, in particular jute fibres, which are formed by suitable needling or casting molds into a porous, interlocking mass are formed.

More recently, luggage using flax fibers and bioplastics has been offered by PRO-JECTKIN ApS, Denmark (website: https://projectkin.com/).

DE 20 2017 004 083 U1 discloses a fiber matrix semi-finished product containing a core of semi-finished fiber layers which are impregnated with at least one matrix component and at least one cover layer of a highly viscous, tough film which is used in the shaping of the component like a deep-drawing film, with which pores which occur when conventional fiber Matrix semi-finished products can arise, be avoided or closed.

However, there is still a need for luggage that improves the environmental performance of conventional luggage systems while maintaining the stability and strength of known constructions and composites.

This problem is addressed and at least partially solved by the various aspects of the present invention.

3. Summary of the Invention

A first aspect of the invention relates to a part of a luggage system, in particular a shell or part of a shell of a hard case or trolley.

In one embodiment, the part of a luggage system comprises a fiber-reinforced material, the fiber-reinforced material comprising a natural fiber material and a matrix material. The natural fiber material comprises at least one set of unidirectional fibers that are incorporated into and/or impregnated with the matrix material.

In most parts of this document, for the sake of simplicity and conciseness, we will simply refer to a "part of the luggage system" (or even more briefly "part of luggage"), but the possibility of an entire luggage system such as a complete hard case or trolley is always included unless otherwise noted.

In addition, the disclosed fiber-reinforced material can be applied to other types of luggage in addition to a shell or part of a shell of a hard-shell suitcase or trolley already mentioned, where a fiber-reinforced material can be used advantageously, for example as a reinforcement in certain areas of a bag or a Suitcases that are otherwise made of a different material, e.g. B. on the edges or corners of the bag or suitcase or in the areas where wheels are attached.

In the context of this document, a natural fibrous material, sometimes referred to as an organic fibrous material, is a fibrous material derived from a plant or other natural object, in contrast to the aforementioned synthetic or chemical-based materials commonly used in the art become. Specific examples of such materials are discussed below.

A set of unidirectional fibers is a set of fibers that are arranged (e.g. by intentional arrangement during manufacture) along a particular preferred direction, as opposed to fibers that are randomly or chaotically arranged, either inherently or after being in such an arrangement were brought, e.g. B. by needling or gigging. Of course, in an actual product, such unidirectional fibers will generally not all be perfectly parallel to this preferential direction either, in the strict mathematical sense of the word "parallel". A certain deviation, the z. B. is unavoidable due to the manufacturing process and / or due to the natural irregularities in the shape of the fibers is accepted, but a recognizable "straightness" of the arrangement of the fibers is provided. The understanding of the term "unidirectional" as used throughout this document can therefore correspond to the natural understanding that those skilled in the art will have of this term.

In addition to the set or sets of unidirectional natural fibers, the natural fiber material can also include other natural fibers in any arrangement, but in a preferred option the natural fiber material is completely encompassed by the one or more sets of unidirectional natural fibers.

The unidirectional fibers may be partially or fully incorporated into the matrix material (suitable matrix materials and their respective properties are discussed below), and/or they may be partially or fully impregnated with the matrix material. Incorporated into the matrix material can be understood as meaning that the fibers are suspended in a bed of matrix material or are "free to move", i. H. the fibers can be interspersed with the matrix material in the interstices between the individual fibers. Being impregnated with the matrix material can be understood in the sense that the matrix material is "soaked up" by the fibres, e.g. so that the fibers become "sticky" and adhere to each other without any appreciable amount of matrix material between the individual fibres is available. Gradations between the two options are of course also possible, i.e. the fibers can be (partially) incorporated into the material matrix or (partially) impregnated with the matrix material.

In addition to the natural fiber material, which comprises the at least one set of unidirectional fibers that are incorporated into and/or impregnated with the matrix material, the fiber-reinforced material can also contain additional materials or components, e.g. B. a (non-organic) textile material to provide further reinforcement in certain areas that are subjected to particularly high loads and forces. In a preferred scenario, however, the fiber-reinforced material contains no other fiber material apart from the natural fiber material or the natural fiber materials.

The part of a luggage system can be made exclusively from the fiber reinforced material. However, the part can also contain further components which consist of or comprise a different material or materials. For example, the part of a luggage system can be a (front and/or rear) shell of a hard case or travel or cabin trolley, which usually consists of a front shell and a rear shell, wherein the shell main body can be made of the disclosed fiber-reinforced material . Additionally, the shell may include, for example, a hinge system, a zipper or closure system, a handle bar or structure, one or more wheels, etc., which may or may not include the disclosed fiber reinforced material.

The natural or organic fibrous materials that can be used in the present invention (some examples are discussed in more detail below) require almost no herbicides and pesticides, very little water to grow and very little energy to harvest and Process, often with little or no harmful chemicals involved. In addition, it is possible, particularly in combination with a matrix material consisting of or comprising a bio-based and biodegradable compound, that the fibers at the end of the luggage system's service life may be degraded by common composting processes that depend on water, ambient temperature, pressure and UV light are dependent on decomposition, extracted from the matrix material and thus either recycled or serve as further soil food.

In addition, with non-directional composites (e.g., fiber-reinforced materials, which have a random arrangement of fibers), the energy upon impact is not evenly distributed in the material, so fracture in the material can propagate in all and multiple directions. This is particularly dangerous for luggage systems such as trolleys, as there are generally no designated impact absorption zones (in other words, an impact can occur anywhere on the luggage and from any direction) and therefore a high risk of damage or even destruction beyond the point of impact possible repair of the trolley when such non-oriented composites are used. Also, with such non-oriented materials, adding bulk in specific areas (i.e. extra layers in the corners of the trolley) is almost always the method used to increase the strength of the material, which is at odds with the principles of sustainability and the always stricter baggage weight restrictions.

In contrast, the set of unidirectional fibers used by the present invention will dissipate the impact energy in a more predictable and controllable manner since each fiber directs the energy in a specific orientation and along the path of least resistance. In addition to being able to orient the fibers so that the energy is dissipated more efficiently from areas where an impact can be considered at least more likely (e.g. at the edges or corners), the unidirectional fibers can also limit the extent of damage, if a break should occur, e.g. B. by directing the fracture in a less critical direction in relation to the overall stability of the luggage/trolley. Therefore, compared to the use of randomly arranged fibers, the unidirectional fibers used in the disclosed material can provide the material with a "stability frame" that increases its overall stability and durability.

Another benefit of using natural fibers in a unidirectional arrangement is that natural fibers are often very strong in the longitudinal direction, but can fray or split or otherwise disintegrate when pulled or stressed in the lateral direction (unlike synthetic fibers, which have this problem). may not exist or only exist to a lesser extent). In this respect too, the use of natural fibers in a suitably chosen unidirectional arrangement (e.g. such that the fibers are loaded predominantly in their longitudinal direction) can therefore contribute to increasing the lifespan of the product compared to the use of natural fibers in a completely random arrangement in which fraying and splitting of the individual fibers can occur to a greater extent.

In this context it is mentioned that the part of a luggage system can also comprise two or more areas in which fiber reinforced materials with a differently oriented set or sets of unidirectional natural fibers are used in order to adapt the specific geometry of these areas and/or the type of impact, likely to occur in these areas, e.g. B. the material composition of the natural fibers and / or the matrix material or other physical and mechanical properties can also change between such areas.

In summary, it can be said that the use of the disclosed fiber-reinforced material using the natural fiber material with the at least one set of unidirectional fibers that are incorporated into and / or impregnated with the matrix material, the advantageous mechanical properties of such an oriented material, especially for construction of luggage systems such as hard cases or trolleys, with the environmental friendliness of natural basic materials.

Further possibilities and modifications of the first aspect of the present invention are now indicated and discussed, whereby these further possibilities and modifications can also be combined with one another in order to obtain the desired material and performance properties of the part of the luggage system, although not each one is described below possible permutation is explicitly listed among the disclosed possibilities. Individual features of sub-features can also be omitted if this does not appear necessary to achieve the desired goal.

For example, the natural fiber material can have n sets of unidirectional (natural) fibers incorporated into and/or impregnated with the matrix material, where n is an integer greater than 1 and where the n sets of unidirectional fibers are non-parallel to one another.

In other words, the natural fibers can provide a multiaxial material, where n is the number of axes. By increasing the number n of axes, the isotropy of the material properties can be increased, possibly at the expense of higher manufacturing costs and complexity, so that there is generally a compromise between stability and isotropy on the one hand and manufacturing costs and complexity, but also weight of the product on the other.

Also in the context of more than one set of unidirectional fibres, it is possible that the part of the luggage system comprises several areas (i.e. two or more) in which different embodiments of the disclosed material are used. To cite a specific example, a shell of a hard suitcase or trolley may comprise on its major surface a fiber reinforced material comprising a natural fiber material with two sets (i.e. n = 2) of unidirectional (natural) fibers incorporated into the matrix material and/or are impregnated with it. At the edges and/or corners and/or where the wheels are attached, the shell may comprise a fiber reinforced material comprising a natural fiber material with three or more sets (i.e. n ≥ 3) of unidirectional (natural) fibers mixed in incorporated and/or impregnated with the matrix material to provide a high degree of stability to these specific areas. The material composition and/or mechanical properties of the natural fibers and/or matrix material may also vary between different regions to further control the properties of the luggage item.

In particular, each set of unidirectional fibers may comprise a plurality of fiber bundles and/or fibrous yarns arranged along a respective axis.

In other words, the fibers can be pre-organized or spun into bundles or yarns which are then aligned and incorporated into the fiber-reinforced material of the luggage. Not only can this facilitate and simplify manufacture, but it can also increase the "directivity" of the fiber reinforced material, thus providing extra strength to the directions defined by the material axis(s).

As already mentioned, two sets of unidirectional (natural) fibers can be used, i. H. n=2, meaning that the natural fiber material is provided as a biaxial fabric or material.

A biaxial material is the simplest case of a multiaxial material, going beyond having just a set of unidirectional fibers oriented along a single axis. It can therefore be manufactured relatively easily, but already provides better isotropy and general stability than a uniaxial material. Especially considering that natural fibers can be more stable in the longitudinal direction (i.e. along the extent of the fibre) than in the lateral/sideways direction, simply adding another axis to the material can significantly increase the stability and longevity of the part of the luggage system. A biaxial material thus provides a light but nevertheless sufficiently stable and easily manufacturable fiber-reinforced material for luggage construction based on natural or organic fibers.

The two axes of the biaxial fabric may intersect at an oblique angle (i.e. an angle other than 90°).

In general, of course, an angle of intersection of the two axes equal to 90° is also possible. However, an oblique cut angle (i.e. ≠ 90°) may also provide the opportunity to combine high overall luggage item stability due to the use of more than one axis with the provision of a further degree of "directivity" or anisotropy. Because the two axes do not intersect at 90°, both an acute angle (i.e., an angle < 90°) and a complementary obtuse angle (i.e., an angle > 90°) are formed between them. For example, the direction defined by the acute angle sector is “closer” to the two axes than the obtuse angle sector, so that greater rigidity/stability can be achieved along the acute angle sector than in the perpendicular direction , i.e. along the angular sector of the obtuse angle. Those skilled in the art will recognize how, using this concept, the physical and mechanical properties of the item of luggage can be influenced not only along the two material axes themselves, but also in the angular segments in between.

Another possibility is that there are three sets of unidirectional (natural) fibers, viz. H. n=3, which means that the natural fiber material is provided as a triaxial material.

An advantage of using three axes (or an even larger number of axes, e.g. n= 4, 5, 6, ..., although a further increase in the ax (The number of points beyond n = 3 could become prohibitive from a design and manufacturing point of view) is that any impact energy leading to an initial rupture of the luggage at a given location will rapidly react with barriers to that energy at the closest intersection or intersections of the different sets of fibres received and thus diverted in three directions. This diversion of energy continues and divides again until it leaves the system or dissipates in the material. In this way, large breaks can be avoided, allowing for repair rather than throwing away. In addition, the overall stability and isotropy of the material is increased compared to using only one or two axes.

Also in this case at least two of the axes of the triaxial fabric can intersect at an angle other than 60°.

In other words, even with more than two axes, the axes (or at least some of them) can intersect at an "irregular" angle, where the "regular" angle for n intersecting axes can be viewed as 360° divided by n ( where the intersection angle can be viewed as the acute angle formed by two intersecting oblique axes, not the complementary obtuse angle).

The fibers contained in the natural fiber material can be continuous.

The continuous fibres, i.e. fibers that have not been torn or cut or otherwise shortened during or after extraction from their natural source, have a very high (tearing) strength in their longitudinal direction (along the extent of the fibre), which is reflected in a correspondingly high stability of the piece of luggage in which they are used. Also, the use of continuous fibers can facilitate the manufacturing process or make it possible in the first place, particularly when the natural fibers are processed to form a woven fabric. However, the use of continuous fibers can also be advantageous for a layered fabric and increase the general tear resistance of the end product along the fiber direction(s). Regardless of the construction of the natural fiber material (woven or layered), the use of continuous fibers can increase the luggage's resistance to uncontrolled damage propagation by directing impact forces along the fiber extent.

The addition of discontinuous and/or particulate (natural and/or synthetic) fibers to the fiber-reinforced material is of course also possible in principle. However, the predominant or exclusive use of continuous natural fibers is advantageous in that it can increase the "directivity" of the fiber-reinforced material and limit the uncontrollable spread of damage already mentioned several times, also from the point of view of sustainability.

The natural fiber material is provided as a layered fabric.

Providing the natural fiber material as a layer can reduce the manufacturing effort, possibly at the expense of a somewhat lower stability of the material. The production could e.g. This can be done, e.g. by wet lay-up, by laying up one or more sheets or layers of oriented fibrous material in a bed of liquid resin which, when cured, forms the matrix material, and then compression molding this preform into the desired shape, e.g. B. by applying pressure and curing the resin by heat, ultraviolet light or a rapid change in humidity until the desired method of curing the resin is applied. Or it can be manufactured via impregnated sheets or layers of fibrous material suspended in or on an epoxy resin, thermoplastic resin or film and then thermoformed into the desired shape.

In addition, each layer can comprise several layers of parallel-oriented, unidirectional fibers. Or only part of the layer consists of several layers of parallel oriented, unidirectional fibers, where the number of layers per layer can vary further between the individual layers.

The stacking of the layers of several layers of parallel oriented, unidirectional fibers can on the one hand lead to simpler production and on the other hand allow finer control of the thickness, density, tear strength, etc. of each individual layer, especially if the number of layers for each layer is controlled individually.

The natural fiber material of the present invention may comprise fibers from one or more of the following materials or plant parts: leaf fibers, bast fibers or stem fibers.

To give some specific examples of these different categories, leaf fibers that can be used in the present invention include abaca, pifia and/or palm fibers, bast fibers that can be used, fibers from hemp, flax, Ramie, kenaf and/or jute, and stem fibers that can be used, fibers from bamboo and/or straw.

More specifically, some examples of natural fiber materials that can be used in the present invention include: a triaxial natural fiber material using flax and/or bamboo fibers, or a biaxial natural fiber material using basalt and/or bamboo fibers. These materials can be used to advantage with the present invention as they provide a good combination of commercial availability, structural and mechanical stability, and a low environmental footprint.

A material composition of the natural fiber material may further vary within a given set of unidirectional fibers and/or between at least two sets of unidirectional fibers. Alternatively or additionally, one or more physical properties, particularly a thickness of the fibers and/or a bulk linear density of the fibers, may vary within a given set of unidirectional fibers and/or between at least two sets of unidirectional fibers.

Flax fibers can e.g. B. be split as split bast into smaller and smaller widths or finenesses, or they can be used without any splitting of the bast. The use of flax may be advantageous from the point of view that flax is readily available commercially.

The same applies to bamboo, which is a straw fiber and has an even greater capacity in the maximum fiber size. The use of bamboo can be considered in particular as a fiber material for local reinforcements due to its higher density, but also as a primary fiber for larger pieces of luggage or whole suitcases that require higher impact resistance.

These possibilities thus allow, beyond the orientation and number of axes (i.e. the number of sets of unidirectional fibers) of the fiber-reinforced material of the present invention used for natural fiber material, to further influence the physical and mechanical properties of the luggage locally and in a controlled manner.

Preferably, the matrix material is biodegradable and/or comprises recycled material. A biodegradable material that provides high impact resistance of the finished piece of luggage is particularly preferred.

One possibility in this regard is the use of a polylactic acid (PLA) thermoplastic film as the matrix material or as part of it.

As already mentioned, the use of a biodegradable matrix material (e.g. a matrix material based on or consisting of the PLA mentioned above) in combination with a reinforcement structure based on a natural fiber material can mean that the entire piece of luggage or at least large parts of it are biodegradable and therefore very appealing from a sustainability point of view. Alternatively, although less preferred from a sustainability point of view, recycled material can also be used (which is usually still better than using virgin materials), which has the advantage of having a larger class of materials to choose from, as biodegradable materials /Plastics are not yet developed to the same extent and are not available in the same number and variety as recyclable plastics.

Bio-based polyethylene (PE), polypropylene (PP), polyamide-6 (PA6), polyamide-n (PA11), polyamide-12 (PA12) and/or polycarbonate (PC) can also be used as matrix material or parts thereof, even if these materials are not (fully) biodegradable, but can at least be more environmentally friendly in terms of their procurement and production (compared to plastics that are e.g. based on petroleum).

In general, however, the matrix material used in a luggage system part according to the invention may comprise one or more of the following materials: an amorphous, crystalline or semi-crystalline thermosetting resin; an amorphous, crystalline or semi-crystalline thermoplastic resin; or a film of one of the aforementioned thermosetting or thermoplastic materials or combinations thereof.

All these materials have their advantages and disadvantages, which are well known to those skilled in the art and can therefore be used and selected depending on the desired properties of the luggage in which they are used. For example, thermoset resins are less preferable from a manufacturing perspective because they require relatively long cycle times to cure, but can provide beneficial properties such as high impact strength in the finished component.

Regardless of the base material(s) from which the natural fibers are made and the chemical composition of the Matrixmate rials can be free of aluminum part of a luggage system according to the invention.

Aluminum has been and is used in large quantities in all types of luggage on the market, be it in the form of whole luggage shells or as corner reinforcement and protection elements, handle systems and so on, while it is notoriously undesirable from a sustainability perspective. The present invention offers an alternative to using this problematic material by providing the discussed fiber reinforced material based on the use of a natural fiber material that can still offer comparable strength and durability to the products in which it is used, but at a significantly lower cost ecological footprint.

A second aspect of the invention relates to a method for producing a piece of luggage or a part of a piece of luggage according to the first aspect.

Those skilled in the art will understand that the embodiments, features and options discussed above in relation to a part of a luggage system according to the first aspect of the present invention generally translate to corresponding features in relation to the manufacture of such a part. The embodiments, features and possibilities discussed above also apply (as far as technically and physically possible) to the second aspect of the present invention now discussed, namely the production of such a part, and will therefore not all be repeated again. Instead, only a few specific embodiments and possibilities as well as advantages of the second aspect are mentioned in somewhat more detail below, and otherwise reference is made to the detailed explanations given above in connection with the first aspect of the invention.

In one embodiment, the method includes the steps of: providing a preform; heating the preform and converting the preform into a mold having dimensions corresponding to the intended shape of the part; closing the mold, preferably using pressure, so that the preform assumes the intended shape of the part; curing the preform or allowing the preform to cure, preferably using: heat, UV light, and/or ultrasonic waves, and/or with a change in: temperature and/or humidity; and opening the mold and demolding the part.

Preferably, curing occurs within the mold, preferably while maintaining at least some or all of the pressure in the mold. However, it is also conceivable to change the order of the method steps and to open the mold before and/or during curing and to demould the part. Or the pressure in the mold can be significantly reduced during curing. Or the mold is opened, but the component remains in the mold to harden.

In addition, the sub-step of heating the preform before it is placed in the mold can also be omitted, e.g. B. when the preform does not need to be heated in order to be manufactured or held moldable (e.g. when the matrix material is still "wet"), and the heating can also, at least partially, occur within the mold and/or when closing the casting done.

As already indicated several times, the part produced in this way can be a shell or a part of a shell of a hard case or trolley, but it can also be the main body or a part of the main body of another type of luggage. It may also be or comprise part of a wheel assembly, a handle system, an internal structure and so on of a piece of luggage, and the dimensions and geometry of the mold will correspond to the nature of the part in a manner which can be readily appreciated by those skilled in the art.

The curing process depends on the composition of the matrix material used and is not further discussed here.

In the event that the natural fiber material is provided as a layered structure, providing the preform may include the steps of providing one or more plies of unidirectional natural fibers and piling up the plies to form a stack of one or more layers of unidirectional fibers, the unidirectional fibers of each layer are arranged along a respective axis, with uncured matrix material being applied to the plies of unidirectional fibers and/or to the layered stack and allowed to be at least partially absorbed by the natural fibers to form the preform.

That is, the uncured matrix material may be provided before, during, or after the stack is laid up. If provided during stratification, it can be added continuously to the growing stack, or after a predefined number of layers have been added, or after some other predefined time interval, for example.

Again, the layers of the stack may all have the same number of plies, or the number of plies (ie sub-layers) may vary between two or more layers.

The layers can already be pre-oriented before being applied to the stack, e.g. B. when stored in a suitable storage container o. Ä., Or they can be placed in the correct orientation directly when applied to the stack.

Providing the preform may further include fusing the locations where the fibers of the various plies or layers within the stack cross or overlap, e.g. B. using: pressure, heat, UV light and/or ultrasonic waves.
Not only can this make preform handling and subsequent steps in the manufacturing process easier, but it can also increase the overall stability and strength of the manufactured part.

In the event that the natural fiber material is provided as a woven structure, providing the preform may include the steps of providing at least one natural fiber material in the form of a woven multiaxial fabric, providing at least one uncured matrix material in the form of a ribbon, sheet or film, and laminating the natural fibrous material to the uncured matrix material, preferably using heat and/or pressure, and allowing the natural fibrous material to at least partially absorb the uncured matrix material to form the preform.

• (a) Die Bastfasern werden entweder als primäres oder sekundäres Landwirtschaftsprodukt geerntet. Bei der sekundären Ernte wird das Primärprodukt (z.B. Leinsamen, Bananen, Cannabis) vom Erntegut getrennt. Abhängig von der Pflanzenart und dem Klima wird dann das unerwünschte Ausgangsmaterial durch verschiedene Verfahren entfernt und anschließend getrocknet. Je nach gewünschter Stofffaserdicke werden die Bestände in kleinere Dimensionen geteilt. Die Fasern werden dann als kontinuierliche Fasern mit einzelnen oder mehreren Arten von Mischungen aufbereitet. Die kontinuierlichen Bastfasern werden zu einem Stoff gewebt, das sich im Webprozess mit anderen Faserarten (z. B. aus Mineralien, Holz oder Bambus) in der gewünschten Mischung, Ausrichtung und Dimension vermischen kann oder nicht.

In any case, the invention enables an environmentally friendly manufacturing process, essentially from agriculture to final processing, for example through one of the following exemplary processes:

• (a) The bast fibers are harvested as either a primary or secondary agricultural product. In secondary harvesting, the primary product (e.g. linseed, bananas, cannabis) is separated from the harvested crop. Depending on the plant species and the climate, the unwanted starting material is then removed using various methods and then dried. Depending on the desired fabric fiber thickness, the stocks are divided into smaller dimensions. The fibers are then conditioned as continuous fibers with single or multiple types of blends. The continuous bast fibers are woven into a fabric that may or may not blend with other types of fibers (e.g. from minerals, wood or bamboo) in the weaving process in the desired blend, orientation and dimension.

One or more thermoplastic resins, which may be petroleum based but preferably organic based, and which may be reinforced with short or long fibers of any origin or otherwise modified to withstand high impact forces, are dried to a desired moisture level/percentage and then through extruded from a die to a desired geometry and dimension, usually as a ribbon or as a continuous sheet.

The thermoplastic sheet or film is then laminated to the woven material, primarily with heat and pressure, until the fibers are impregnated with the thermoplastic resin, and then partially cooled and cut to the desired dimensions.

• (b) Alternativ könnte die Vorform mit einer oder mehreren Schichten aus Fasern beschichtet werden und dann könnte flüssiges Epoxid durch alle Schichten der Vorform hindurch aufgetragen werden, um die Fasern zu imprägnieren und als Bindemittel zu fungieren, das sich ähnlich wie ein thermoplastisches Harz verhält. Die Nassauflegematrix aus Faserschichten und Epoxidharz könnte direkt auf eine dreidimensionale Gussform aufgebracht werden oder in einem flachen Zustand vorbereitet und dann auf eine dreidimensionale Gussform bewegt werden. Die dreidimensionale Gussform weist in der Regel mindestens zwei Teile auf, in der Regel eine männliche und eine weibliche, zwischen denen sich ein Gussformholraum befindet. Wärme und Druck würden dann auf die Teile des Holraumes angewendet werden, um das Epoxidharz in der gewünschten Form auszuhärten.

This preform is then used in a thermoforming process in which a three-dimensional mold and the preform meet, and heat and pressure are used to shape the material into the desired part.

• (b) Alternatively, the preform could be coated with one or more layers of fibers and then liquid epoxy could be applied through all the layers of the preform to impregnate the fibers and act as a binder, behaving similarly to a thermoplastic resin. The wet lay-up matrix of fiber layers and epoxy could be applied directly to a three-dimensional mold or prepared in a flat state and then moved to a three-dimensional mold. The three-dimensional mold typically has at least two parts, typically a male and a female, with a mold cavity between them. Heat and pressure would then be applied to the parts of the cavity to set the epoxy in the desired shape.

• (c) Nach einem der beiden Gussformverfahren können die überschüssigen Materialien weggeschnitten und weitere Löcher in das geformte Teil geschnitten werden, um eine beliebige Anzahl von anderen Bauteilen und Befestigungselementen sowohl innen als auch außen in der endgültigen Baugruppe zu montieren.

Additionally, it would also be conceivable to impregnate the fibers with a resin/epoxy and then align the fibers (e.g. similar to a weaving process) and then heat and pressure or through any places where the impregnated fibers overlap To merge pressure and frequency similar to ultrasonic welding. This preform could then be thermoformed in either a wet or a dry process.

• (c) After either of the two molding processes, the excess materials can be removed and additional holes cut in the molded part to mount any number of other components and fasteners both internally and externally in the final assembly.

A third aspect of the invention relates to a method for repairing a luggage system or a part of a luggage system according to the first aspect of the invention which has been damaged.

The person skilled in the art also understands for this third aspect that the embodiments, features and possibilities discussed above in relation to a part of a luggage system according to the first aspect of the present invention and/or a method according to the second aspect of the present invention generally relate to corresponding features the repair of such a part are transferrable. Therefore, only a few specific embodiments and possibilities as well as advantages of the third aspect of the invention are briefly mentioned below, and otherwise reference is made to the detailed explanations given above in connection with the first and/or second aspect of the invention.

In one embodiment, the method of repair includes the steps of: adding uncured matrix material to the damaged area of the part; allowing the natural fibrous material in the damaged area to at least partially absorb the added uncured matrix material; applying pressure to the damaged area (e.g., to further facilitate absorption of the uncured matrix material and/or to deform the damaged area into the desired shape); and curing or allowing the added uncured matrix material to cure, preferably using: heat, UV light, and/or ultrasonic waves, and/or with a change in: temperature and/or humidity.

In another embodiment, the method of repair includes the steps of: adding uncured matrix material to the damaged area of the part; allowing the natural fibrous material in the damaged area to at least partially absorb the added uncured matrix material; and curing or allowing the added uncured matrix material to cure, preferably using: pressure, heat, UV light, and/or ultrasonic waves, and/or with a change in: temperature and/or humidity.

The two just-mentioned embodiments differ essentially in the way the pressure is used during the process: in the first embodiment, the damaged area is subjected to pressure before the curing process, while in the second embodiment, pressure can be applied during the curing process or not. Which option is more appropriate, and whether the application of pressure is necessary at all, can depend on the size and shape of the part and the damaged area, as well as the composition of the matrix material and the nature of the curing process.

In conventional mineral or plastic based fiber reinforced materials, the fiber itself is typically relatively hydrophobic and cannot incorporate resin into the fiber nearly as well as a natural or organic fiber with its cellular structure. In addition, mineral fibers are comparatively brittle. Should a piece of luggage containing such material break, it is seldom possible to repair the part, as patching such an area would require adding material to the top and bottom of the affected area, with the original substrate in between. In addition, to increase strength, holes must be made in the composite, which have a very high risk of becoming a new weak point that will not withstand repeated impacts.

The use of natural fibers as dictated by the present invention overcomes this problem as natural fibers are typically hygroscopic and thus can absorb more resin in the fracture areas during the repair/patching process than fibers made from mineral or synthetic materials. This makes it possible to strengthen and not weaken the part to be repaired. Additionally, the repair process can potentially occur many times, and when the repair process is deemed exhausted or not economically feasible, the luggage item may be fully or at least substantially compostable or biodegradable, as discussed above.

In this context z. B. Components such as fabrics, handles and wheels comprising the disclosed fiber reinforced material with the natural fiber material can be reused (e.g. after wear) to repair trolley shells made from this material.

character list

• 1a-b: Beispiele für ein faserverstärktes Material umfassend ein Naturfasermaterial und ein Matrixmaterial, das in einem erfindungsgemäßen Teil eines Gepäcksystems verwendet werden kann;
• 2: Beispiel für ein erfindungsgemäßes Verfahren zur Herstellung eines erfindungsgemäßen Teils eines Gepäcksystems;
• 3: Weiteres Beispiel für ein erfindungsgemäßes Verfahren zur Herstellung eines erfindungsgemäßen Teils eines Gepäcksystems;
• 4: Beispiel für ein erfindungsgemäßes Teil eines Gepäcksystems mit einem biaxialen, gewebten Naturfasermaterial; und
• 5a-h: Beispiel für ein erfindungsgemäßes Gepäcksystem in Form eines Reise- oder Kabinentrolleys.

Possible embodiments of the present invention are described in more detail with reference to the following figures:

• 1a-b : Examples of a fiber-reinforced material comprising a natural fiber material and a matrix material that can be used in a part of a luggage system according to the invention;
• 2 : example of a method according to the invention for producing a part of a luggage system according to the invention;
• 3 : Another example of a method according to the invention for producing a part of a luggage system according to the invention;
• 4 : Example of a part of a luggage system according to the invention with a biaxial, woven natural fiber material; and
• 5a-h : Example of a luggage system according to the invention in the form of a travel or cabin trolley.

5. Detailed description of possible embodiments

Possible embodiments of the various aspects of the present invention are described below, primarily in relation to travel or cabin trolleys. However, it is again emphasized that the various aspects of the present invention can also be practiced in other types of luggage systems and are not limited to the embodiments presented below.

It is also pointed out that only individual embodiments of the invention can be described in more detail below. However, the person skilled in the art will understand that the features, possibilities and possible modifications described with reference to these embodiments can also be further modified and/or combined with one another in other ways or in other sub-combinations without departing from the scope of the present invention. Individual features or sub-features can also be omitted if they are considered dispensable to achieve the desired result. In order to avoid redundancies, reference is therefore made to the explanations in the previous sections, which also apply to the following detailed description.

1a-b show examples of fiber-reinforced materials 100a, 100b and 100c, comprising a natural fiber material with at least one set of unidirectional fibers incorporated into and/or impregnated with a matrix material, which can be used in a part of a luggage system according to the present invention (examples for such parts are in 4 and in the 5a-h shown).

1a Figure 1 shows a fiber reinforced material 100a comprising a natural fiber material comprising continuous natural fibers 110a. Discontinuous and/or particulate fibers may also be added to the fiber-reinforced material 100a, but this is not shown and discussed further here.

The continuous natural fibers 110a can be provided as a plurality of fiber bundles/fibrous yarns. The natural fibers 110a form in 1a a set 120a of unidirectional fibers arranged along the longitudinal direction 101a. also in 1a shows the transverse direction 102a, which is perpendicular to the longitudinal direction 101a. In the case of the part of a luggage system made from or comprising the material 100a, the longitudinal direction 101a can, for example, be arranged along the direction of the greatest spatial extent of the part, but this does not necessarily have to be the case. In other words, the terms "longitudinal" and "transverse" are used primarily for clarity and clarity, but do not necessarily dictate any particular placement of the material 100a within the portion of a luggage system in which it is used . The longitudinal direction 101a can also be arranged obliquely or diagonally to the edges of a shell of a hard case or trolley in which the material 100a is used (eg in one of the shells 510, 520 of the trolley 500 described below).

The fibers 110a of the set 120a are incorporated into a matrix material 130a. The fibers 110a can also have “absorbed” the matrix material 130a and thus be impregnated with the matrix material 130a. While in the in 1a In the situation illustrated, the fibers 110a are completely incorporated into the matrix material 130a, ie are completely contained therein (apart perhaps from their beginnings and ends), this does not necessarily have to be the case in all situations. In other words, the fibers 110a can also only be partially incorporated into the matrix material 130a, or be “on top” of the matrix material 130a, or only contain matrix material 130a in their interior, ie only be impregnated with the matrix material 130a, but on their Outside of no matrix material 130a surrounded or incorporated therein. These statements also apply to fiber-reinforced materials containing more than one set (ie n sets with n > 1) of unidirectional fibers, eg materials 100b and 100c discussed below, although this is not explicitly repeated each time.

The fibers 110a of the natural fiber material can, for. B. comprise one or more of the following materials: leaf fibers, bast fibers or stem fibers.

For example, the use of flax, which is a bast fiber, for the fibers 110a (or any of the natural fibers discussed herein) may be advantageous given that flax is readily commercially available. The use of bamboo, which is a stem fiber, can also be considered, particularly as a fiber material for local reinforcement, due to its higher density, but also as a primary fiber for larger pieces of luggage or whole suitcases that require greater impact resistance.

The matrix material 130a may include one or more of the following materials: an amorphous, crystalline, or semi-crystalline thermoset resin; an amorphous, crystalline or semi-crystalline thermoplastic resin; or a film of one of the aforementioned thermosetting or thermoplastic materials or combinations thereof. Preferably, the matrix material 130a is biodegradable and/or comprises recycled material.

A particular possibility is the use of PLA as the matrix material 130a or at least as the basis for the matrix material 130a due to its known biodegradability. In general, biodegradable and high impact bio-based thermoplastics or resins are well suited for the present invention.

Partially or fully bio-based PE, PP, PA6, PA11, PA12 and PC materials can also be considered as alternatives, which are not (completely) biodegradable but are still more environmentally friendly than e.g. B. conventional plastics based on petroleum.

1b Figure 12 shows another fiber reinforced material 100c comprising a natural fiber material comprising continuous natural fibers 110c. Discontinuous and/or particulate fibers may also be added to the fiber reinforced material 100c, but this is not shown and discussed further here.

The continuous natural fibers 110c may be provided as a plurality of fiber bundles/fibrous yarns 115c. The natural fibers 110c form n sets of unidirectional fibers, where for the in 1C In the embodiment shown, n=4, ie there are four sets 120c, 121c, 122c and 123c of unidirectional fibers, each set being arranged along a respective axis or direction. The filaments of two of the four sets 120c, 121c, 122c, 123c of unidirectional yarns are not parallel to each other, ie they intersect at a non-zero angle. The fibers 110c are incorporated into and/or impregnated with a matrix material 130c.

A modification (not shown) of the material 100c would have three sets of unidirectional fibers 110c instead of four (i.e., n=3, a triaxial fabric), with the fibers of two of the three sets of unidirectional yarns being non-parallel to one another, i. H. they intersect at an angle other than 0°. Preferably at least two of the three sets would also intersect at an angle other than 60°, with the consequent technical advantages discussed in Section No. 3 above, which is therefore incorporated herein by reference.

In the material 100c, the natural fiber material is provided as a layered fabric, wherein in the embodiment of FIG 1b eight layers 140c through 147c are shown. Each of the layers 140c, 141c, ..., 147c further includes multiple layers of parallel-oriented, unidirectional fibers 110c, identified as layer #1 through layer #48 in 1b are designated. In other words, in the embodiment of 1b each of the layers 140c, 141c, ..., 147c comprises six plies.

• - Der erste Satz 120c umfasst Schichten 140c und 147c mit Lagen Nr. 1-6 und Nr. 43-48, in denen die Fasern in einem Winkel von 0° bezüglich der Querrichtung (die hier ohne Verlust der Allgemeinheit als Bezugspunkt genommen wird) angeordnet sind.
• - Der zweite Satz 121c umfasst Schichten 141c und 146c mit Lagen Nr. 7-12 bzw. Nr. 37-42, in denen die Fasern in einem Winkel von +45° bezüglich der Querrichtung angeordnet sind.
• - Der dritte Satz 122c umfasst Schichten 142c und 145c mit Lagen Nr. 13-18 bzw. Nr. 31-36, bei denen die Fasern in einem Winkel von +90° zur Querrichtung angeordnet sind.
• - Der vierte Satz 123c umfasst Schichten 143c und 144c mit Lagen Nr. 19-24 bzw. Nr. 25-30, in denen die Fasern in einem Winkel von -45° zur Querrichtung angeordnet sind.

In the embodiment of 1b each of the four sets 120c, 121c, 122c, 123c of unidirectional fibers includes two of the layers 140c, 141c, ..., 147c:

• The first set 120c comprises layers 140c and 147c with plies #1-6 and #43-48 in which the fibers are arranged at an angle of 0° with respect to the transverse direction (taken here as a reference point without loss of generality). are.
• - The second set 121c comprises layers 141c and 146c with plies No. 7-12 and No. 37-42 respectively, in which the fibers are arranged at an angle of +45° with respect to the transverse direction.
• - The third set 122c comprises layers 142c and 145c with plies #13-18 and #31-36, respectively, in which the fibers are arranged at an angle of +90° to the transverse direction.
• - The fourth set 123c comprises layers 143c and 144c with plies #19-24 and #25-30, respectively, in which the fibers are arranged at an angle of -45° to the transverse direction.

Here too (ie also for the situation n > 2) a material composition of the natural fibers 110c or fiber bundles/fibrous yarns 115c can vary between two (or more) of the sets 120c - 123c, and also within one given one of the sets 120c-123c of unidirectional fibers (eg, between different layers or even different plies comprised in one of the sets, or even within a given ply). Alternatively or additionally, one or more physical properties, such as a thickness of the fibers 110c and/or a linear bulk density of the fibers 110c, within a given one of the sets 120c-123c and/or between two (or more) of the sets 120c-123c of unidirectional Fibers vary.

2 and 3 show schematic representations of examples of a method 200, 300 according to the invention for producing a part of a luggage system according to the invention (examples of such parts are in 4 and in the 5a-h shown).

The procedure 200 of 2 begins, generally provided by the reference numeral 210, with the provision of input materials at a production facility for the manufacture of a preform 20 for the manufacture of the luggage item 21. The step 210 of providing the input materials can in particular the provision of at least one natural fiber material in the form of a woven multiaxial fabric as well as comprise providing at least one uncured matrix material in the form of a tape, sheet or foil.

Other materials and components that may be provided in step 210 include, for example: adhesives, such as adhesive powder, adhesive films, web adhesive; cut glass; textile materials for further reinforcement; foil material.

The method 200 further includes the step of laminating the natural fiber material with the uncured matrix material and allowing the natural fiber material to at least partially absorb the uncured matrix material to form the preform 20, indicated generally by reference numeral 220. In FIG 2 In the method 200 shown, lamination is performed using heat (see reference numeral 221) and pressure (see reference numeral 222), and the laminated structure is then cooled (see reference numeral 223) to stabilize the preform 20.

The preform 20 may be stored in roll or sheet form, as indicated generally at reference numeral 230 .

After the preform 20 has been provided in this way, the method 200 further includes the (optional) step of heating the preform 20 (the heating may also occur, at least partially, within the mold 22 and/or during the closing of the mold 22, or completely may be omitted if not required to render or maintain the preform 20 formable), and the method 200 includes the step of transferring the preform 20 into a mold 22 having dimensions corresponding to the intended shape of the part to be produced . This step is indicated generally at reference numeral 240 . The mold 22 is then closed, as indicated at reference numeral 250, preferably with the application of pressure, so that the preform 20 assumes the shape and geometry defined by the mold cavity, i. H. The intended shape of the part to be manufactured (at least its general shape; further post-processing steps may follow on the demolded part, which may also further modify the shape and geometry of the part). The preform 20 is then cured or allowed to cure in the mold 22 (the mold pressure may or may not be maintained during curing), preferably with the use of heat, UV light, and/or ultrasonic waves, and/or with manipulation of temperature and/or humidity as indicated at reference numeral 260. Finally, as indicated at reference numeral 270 , the mold 22 is opened and the molded part 21 of a luggage system is removed from the mold 22 . After the demoulding step 270, as already indicated above, further processing can take place, e.g. e.g. the part 21 can be trimmed or reworked, holes or other components can be inserted, etc.

This in 3 The illustrated method 300 begins in turn, indicated generally by reference numeral 310, with the provision of input materials at a manufacturing facility for preparing a preform 30 for the manufacture of the luggage item 31. The step 310 of providing the input materials this time includes providing one or more layers of unidirectional natural fibers . The method further includes stacking the layers to form a stack of one or more layers of unidirectional fibers, the unidirectional fibers of each layer being arranged along a respective axis. This step is in 3 indicated generally by the reference numeral 320 . Uncured matrix material is applied to the layers of unidirectional fibers and/or to the layered stack as in 3 indicated generally by the reference numeral 330 and allowed to be at least partially absorbed by the natural fibers to form the preform 30. It is emphasized that the order of steps 320 and 330 can also be different than shown here, ie the uncured matrix material can also be be provided before or during stacking of the layers in step 320.

In addition, the method 300 may also include the step of fusing the locations where the fibers of the various plies or layers within the stack cross or overlap using: pressure, heat, UV light, and/or ultrasonic waves ( in 3 not shown).

From there, the method 300 may proceed in a manner similar to the method 200 described above: the preform 30 as just provided may be heated (the heating may also occur, at least partially, within the mold 32 and/or during the closing of the mold 32 or omitted entirely if not necessary to render or maintain the preform 30 formable) and the preform 30 is then transferred to a mold 32 having dimensions corresponding to the intended shape of the part to be produced. This step is indicated generally by reference numeral 340 . The mold 32 is then closed, as indicated by reference numeral 350, preferably with the application of pressure, so that the preform 30 assumes the shape and geometry defined by the mold cavity and hence the intended shape of the part to be produced (again, further post-processing of the demolded partially done). The preform 30 is then cured or allowed to cure in the mold 32 (again, mold pressure may or may not be maintained during curing), preferably using heat, UV light, and/or ultrasonic waves, and/or under a change in temperature and/or humidity as indicated at reference numeral 360. Finally, as indicated by reference numeral 370 , the mold 32 is opened and the molded part 31 of a luggage system is removed from the mold 32 . After the demoulding step 370, further processing can take place again, e.g. e.g. the part 31 can be trimmed or reworked, holes or other components can be added etc.

The duration and processing parameters for the various steps of the thermoforming/casting process, i. H. steps 240-270 and 340-370, e.g. B. depend on the physical dimensions and the pressing capabilities of the mold equipment and the materials used for manufacture. So e.g. B. the duration of the mold closing step 250, 350 depend on the pressing capabilities (e.g. maximum closing pressure) and the impregnation behavior of the natural fibers contained in the preform 20, 30, while the duration of the curing step 260, 360 depends on the chemical composition of the matrix material, the curing temperature within the mold, the duration and amount of pressure applied during the previous step 250, 350, the mold pressure during curing, and so on.

Some of the steps provided by methods 200, 300 for manufacturing a part of a luggage system can also be used, possibly in a slightly modified version, to provide a method for repairing a damaged part of a luggage system.

Such a method may include adding uncured matrix material to the damaged area of the part and allowing the natural fiber material in the damaged area to at least partially absorb the added uncured matrix material (e.g., similar to step 330 of method 300).

Pressure can then be applied to the damaged area, e.g. B. within a mold (eg, similar to step 250 of the method 200 or in step 350 of the method 300) or in another way.

The repair process may further involve curing the added uncured matrix material or allowing curing while, after or without the application of pressure and preferably using: heat, UV light and/or ultrasonic waves, and/or under a change of: temperature and /or humidity (e.g. similar to step 260 of method 200 or step 360 of method 300).

4 Figure 4 shows part 400 of a luggage system made from a fiber reinforced material as disclosed herein. For example, the part can be used as a front or rear insert for the main surface of a shell of a hard case or trolley, such as the Trolley 500 described below. The fiber reinforced material consists of a natural fiber material and a matrix material, the natural fiber material comprising two sets of unidirectional natural fibers, provided in the form of fibrous yarns woven into a biaxial woven fabric. This substance is incorporated into the matrix material and impregnated with it.

At the in 4 The part 400 shown uses a biaxial natural fiber material 410 using flax fibers in combination with a thermosetting epoxy resin as the matrix material.

down in 4 is a similar part 405 after demolding (e.g., after step 270 of the method rens 200 or step 370 of method 300) but prior to being trimmed to its final dimensions to better show the woven structure of the included biaxial flax fiber material 410.

Finally show the 5a-h a luggage system, namely a travel or cabin trolley 500, using a fiber reinforced material disclosed herein, eg one of the materials 100a, 100b or 100c discussed above.

The trolley 500 generally consists of a front shell 510 and a rear shell 520 which are connected to one another in such a way that the two shells 510, 520 can be opened and closed on one another. The trolley 500 also includes a means for closing, in the embodiment shown here a zipper mechanism 530, to secure the two shells 510, 520 in their closed position.

The trolley 500 also includes four rotating wheels 540 mounted in corresponding indentations 545 at the four bottom corners of the front and rear shells 510,520.

The trolley 500 also includes a retractable handlebar system 550 for towing the trolley 500 on its wheels, and a side handle assembly 560 for carrying the trolley 500 by hand.

A recess or storage space 570 can be arranged below the handlebar system 550, which is accessible in the extended position of the handlebar system 550 (see FIG 5d ) and in which, for example, a USB power bank can be stored in a reusable manner. At this point, reference is made expressly to the disclosure in the earlier applications DE 20 2017 101 957 U1 and WO 2018 185016 A1 referred to the applicant, whose disclosure with regard to the handle bar system 550 and the storage space 570 of the trolley 500 is hereby adopted.

5a shows the front shell 510 without the additional components (wheels, handlebar system, zipper, etc.), 5b shows the rear shell 520 without the additional components. Either or both of these shells 510, 520 can be made in accordance with the present invention, ie, using an embodiment of the disclosed fiber-reinforced material based on natural fibers, such as material 100a, 100b, or 100c described above. Preferably, both shells 510 and 520 are made of such a material.

5c shows a front view of the entire trolley 500 with all other components and 5d a rear view of the entire trolley 500, each with the handlebar system 550 in the extended or extended position.

5e shows the right side surface (relative to the front) of the trolley 500 with all other components and 5f the left side surface. 5g finally shows the top of the trolley with all other components and the handle bar system 550 in the retracted or pushed-in position and 5h a view from below.

Besides the front and rear shells 510 and 520, any or all parts of the trolley 500 may include, be based on, or be made of the disclosed fiber reinforced material.

In this way, the disclosed materials and methods can enable the provision of a trolley 500 that is free of aluminum or at least with a significantly reduced proportion of aluminum and is based entirely or at least predominantly on natural and biodegradable materials. This reduces the environmental footprint left by the luggage system 500 both at the beginning and at the end of its lifespan.

Claims (21)

Part (21; 31; 400) of a luggage system, in particular shell (510; 520) of a hard case or trolley (500), comprising a fiber-reinforced material (100a; 100b; 100c), the fiber-reinforced material comprising: 1a. a natural fiber material (110a; 110b; 110c); and 1b. a matrix material (130a; 130b; 130c), wherein 1C the natural fiber material comprises at least one set (120a; 120b-121b; 120C-123e) of unidirectional fibers incorporated into and/or impregnated with the matrix material; and i.e. wherein the natural fiber material is provided as a layered fabric. part of a luggage system claim 1 wherein the natural fiber material comprises n sets of unidirectional fibers incorporated into and/or impregnated with the matrix material, wherein n is an integer greater than 1 and wherein the n sets of unidirectional fibers are non-parallel to each other. part of a luggage system claim 1 or 2 , wherein each set of unidirectional fibers comprises a plurality of fiber bundles and/or fibrous yarns arranged along a respective axis. part of a luggage system claim 2 or 3 , where n = 2 and the natural fiber material is provided as a biaxial fabric. part of a luggage system claim 4 , where the two axes of the biaxial fabric intersect at an oblique angle. part of a luggage system claim 2 or 3 , where n = 3 and the natural fiber material is provided as a triaxial fabric. part of a luggage system claim 6 , where at least two of the axes of the triaxial fabric intersect at an angle other than 60°. Part of a luggage system according to any of Claims 1 until 7 , where the fibers are continuous. part of a luggage system claim 1 , wherein each layer comprises multiple layers of parallel-oriented, unidirectional fibers. Part of a luggage system according to any of Claims 1 until 9 wherein the natural fiber material comprises fibers of one or more of the following materials: leaf fibers, bast fibers or stem fibers. Part of a luggage system according to any of Claims 1 until 10 wherein a material composition of the natural fiber material varies within a given set of unidirectional fibers and/or between at least two sets of unidirectional fibers. Part of a luggage system according to any of Claims 1 until 11 wherein one or more physical properties, particularly a thickness of the fibers and/or a bulk linear density of the fibers, varies within a given set of unidirectional fibers and/or between at least two sets of unidirectional fibers. Part of a luggage system according to any of Claims 1 - 12 , wherein the matrix material is biodegradable and/or comprises recycled material. Part of a luggage system according to any of Claims 1 until 13 wherein the matrix material comprises one or more of the following materials: an amorphous, crystalline, or semi-crystalline thermoset resin; an amorphous, crystalline or semi-crystalline thermoplastic resin; or a film of one of the aforementioned thermosetting or thermoplastic materials or combinations thereof. Part of a luggage system according to any of Claims 1 until 14 , where the part is free of aluminum. Method (200; 300) for producing a part of a luggage system according to one of Claims 1 - 15 , the method comprising: 16a. providing a preform; 16b. heating the preform and converting (240; 340) the preform into a mold (22; 32) having dimensions corresponding to the intended shape of the part; 16c. closing the mold (250; 350), preferably using pressure, so that the preform assumes the intended shape of the part; 16d. curing (260; 360) the preform or allowing the preform to cure, preferably using: heat, UV light, and/or ultrasonic waves, and/or with a change in: temperature and/or humidity; and 16e. opening (270; 370) the mold and demolding the part. procedure after Claim 16 , wherein providing the preform comprises the following steps: 17a. providing (310) one or more layers of unidirectional natural fibers; and 17b. stacking (320) the layers to form a stack of one or more layers of unidirectional fibers, the unidirectional fibers of each layer being arranged along a respective axis; wherein 170. uncured matrix material is applied (330) to the layers of unidirectional fibers and/or to the layered stack and allowed to be at least partially absorbed by the natural fibers to form the preform. procedure after Claim 17 wherein providing the preform further comprises fusing the locations where the fibers of the various plies or layers within the stack cross or overlap using: pressure, heat, UV light, and/or ultrasonic waves. procedure after Claim 16 , wherein providing the preform comprises the following steps: 19a. providing (210) at least one natural fiber material in the form of a woven multiaxial fabric; 19b. Providing (210) at least one uncured matrix material in the form of a ribbon, sheet or a foil; and 190. laminating (220) the natural fiber material to the uncured matrix material, preferably using: heat and/or pressure, and allowing the natural fiber material to at least partially absorb the uncured matrix material to form the preform. Method for repairing a part of a luggage system according to any one of Claims 1 - 15 which has been damaged, the method comprising: 20a. adding uncured matrix material to the damaged area of the part; 20b. allowing the natural fiber material in the damaged area to at least partially absorb the added uncured matrix material; 20c. applying pressure to the damaged area; and 20d. curing the added uncured matrix material or allowing it to cure, preferably using: heat, UV light and/or ultrasonic waves, and/or under a change of: temperature and/or humidity. Method for repairing a part of a luggage system according to any one of claims 1 - 15 which has been damaged, the method comprising: 21a. adding uncured matrix material to the damaged area of the part; 21b. allowing the natural fiber material in the damaged area to at least partially absorb the added uncured matrix material; and 21c. curing the added uncured matrix material or allowing it to cure, preferably using: pressure, heat, UV light and/or ultrasonic waves, and/or under a change of: temperature and/or humidity.

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